Motor Thermal Management via Conductive Sheet Gap Filling
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Solution Overview
Problem
Existing methods for electric superchargers face challenges in simultaneously addressing heat dissipation and vibration noise, as thermally conductive materials either fail to effectively dissipate heat or transmit vibrations, and flexible materials compromise cooling efficiency.
Innovation Solution
A motor design incorporating a thermally conductive sheet, such as a graphite sheet, laminated to form an elastic body that fills the gap between the motor housing and stator, providing high thermal conductivity and tensile modulus to enhance both cooling and vibration suppression, with adjustable shape and size for easy assembly and precise placement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a thermally conductive member made of metal is filled in the gap between the stator and the motor housing to dissipate heat, then the cooling effect is improved, but vibration is transmitted to the outside of the motor housing and noise increases
Solution Approach 1:
The patent uses a composite structure consisting of a thermally conductive sheet (providing heat dissipation) combined with a vibration suppression sheet (providing noise reduction). This composite material approach allows simultaneous achievement of thermal conductivity and vibration isolation, resolving the contradiction between cooling effect and noise reduction.
2Object-generated harmful factors
If a flexible material is interposed between the stator and the motor housing to suppress vibration, then noise is reduced, but the motor cooling effect deteriorates
Solution Approach 1:
The patent employs a composite structure where a vibration suppression sheet (flexible material) is combined with a thermally conductive sheet. The vibration suppression sheet reduces noise while the thermally conductive sheet maintains effective heat dissipation, thus resolving the contradiction between noise reduction and cooling effect.
3Temperature
If a thermally conductive resin is used to fill the gap between the stator and the housing section, then heat dissipation is achieved, but high friction occurs during insertion and the heat dissipation effect is not sufficiently high
Solution Approach 1:
The patent uses a thermally conductive sheet in the form of a flexible thin film that can be easily inserted into the gap between the stator and housing section. This sheet form provides sufficient thermal conductivity while minimizing friction during insertion, resolving the contradiction between heat dissipation effectiveness and ease of manufacture.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution effectively improves both cooling efficiency and vibration suppression, allowing for easy assembly and reduced noise transmission while maintaining high thermal conductivity and tensile strength, thus addressing the dual challenges of heat dissipation and vibration.
Implementation Method 1
filling a thermally conductive member made of a thermally conductive material such as metal in the gap between the stator and the motor housing such that heat of the motor body is dissipated outside via the thermally conductive member
Implementation Method 2
the thermally conductive sheet includes a graphite sheet. With the above configuration (2), a graphite sheet has a high thermal conductivity and a high tensile modulus of elasticity and thus is elastic, whereby it is possible to improve both of the cooling effect from heat dissipation of the motor and the vibration suppression effect
Data Source
AI summary
A motor includes: a motor housing; a stator disposed inside the motor housing and supported by the motor housing; and a thermally conductive sheet disposed so as to fill a gap in a radial direction or an axial direction between the motor housing and the stator.